The project has run for 48 months. These are the main results:
In WP1 “Requirements and specifications”, the industrial processes were thoroughly described, the critical quality indicators for each product were identified, as well as the critical process parameters. This information was compiled in Application Project Charters.
In WP2, “Real-time simulation modelling”, complex physics-based models were developed and converted into real-time apps. The final result is a model that runs in real time providing a solution for the output variables of interest as a function of the input parameters.
In WP3, “Online data gathering systems and data-driven models”, innovative sensors and instruments were developed to gather online, in real-time, the input parameters for the ROMs. Some of these input parameters are not straightforward to identify or to measure, as they are “hidden” variables that need the development of innovative ways for measuring them in a non-destructive way. Traceability systems were developed and installed in order to generate correlated data sets that were used to extract data-driven models.
Within WP4 “Adaptive control”, optimisation and decision-making algorithms were developed. The former are needed for the calculation in real time of the value of the process parameters that adjust the performance to the target value, based on the output of the real-time simulation models. The latter generate alarms, warnings and recommendations, based on the predictions of the DDMs. Additionally, recalibration algorithms were developed to adjust the values of unknown ROM parameters based on the measurements coming from the line, to increase the model accuracy. Finally, a data management platform (iSCAN) that integrates the info from the modules and sensors, and hosts the recalibration module and the visualisations (iDashboards) was put in place.
Within WP5 “Integration”, all the previous modules and systems were integrated in the pilot production lines and tested, first offline or in open-loop or through the use of virtual lines, before proceeding with the final tests in closed-loop. User interfaces were built for the three lines to allow users to monitor on-line data (historical and real-time), interact with the STREAM-0D modules and see in real-time the alarms and predictions from the DDMs and ROMs.
Within WP6 ”Demonstration”, the performance of the STREAM-0D solution has been assessed through the manufacturing of a number of parts, including the manufacturing of different references, so that not only the performance of the ROMs and DDMs has been validated, but also the time needed to change the line for producing a new product reference. Other indicators have been analysed, such as the variation in productivity, cycle time, end-of-line tests, production costs, waste and rejections that results from the implementation of the STREAM-0D solution.
Within WP7,“Dissemination, exploitation and IPR management”, a detailed plan for the identification, protection and exploitation of results has been completed as well as a deatiled business plan for the further deployment of the STREAM-0D solution after the project. All the necessary tools and activities for communication purposes have been put in place.
